Hot ultrasonic assisted machining modelling of Ti6Al4V in terms of power consumption

Ultrasonic assisted machining is a manufacturing method which creates intermittent cutting mechanism using ultrasonic vibration. Hot machining is another technique which uses external heat source before or during machining operations. These methods help to machine difficult to cut materials such as titanium, nickel, composite materials and improve surface machining characteristics (low cutting force, stress level, etc.). Hot ultrasonic-assisted machining is a novel machining technique that combines Ultrasonic Assisted machining (UAT) and hot machining operations. In the present study, Hot Ultrasonic Assisted Turning (HUAT) of Ti6Al4V alloy was studied numerically via DEFORM-2D software. Cutting speed, feed rate, vibrational parameters, and preheating temperatures were chosen as cutting parameters for the simulation study. Cutting forces, maximum effective stresses, and cutting temperatures were calculated with respect to these parameters. This process has also been investigated in terms of its effect on the environment and energy consumption. Cutting speed, feed rate and preheating temperatures affect machining characteristics while vibrational parameters do not affect significantly. Decrease in cutting speed and feed rate leads to lower power consumption. Also, power consumption changes with the increase in heating temperature and vibration frequency/amplitude.